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Major projects

We have worked with .............. 

2023 - RSS 18404 Six Sigma Green Belt with Lean Practitioner course - accredited. 

2023 - NHS consultancy, working with Universities

October 2021 - 2023 ongoing Consultancy support and training for a major medical supplier within Europe


October 2021 - August 2022 Consultancy support for electric vehicle project across Europe.


October 2021 - Relaunch after Covid-19  

March 2020 - Launch of Portfolio of Virtual Training courses for Business and Continuous Professional Development CPD.

July 2017 – March 2020 Mahle-Behr France Leading a cultural change programme using Six Sigma and Lean tools and techniques across production cells to allow for the introduction of Industry 4.0. Working across the total value chain from suppliers to the customers understanding and solving complex problems towards the business goals. This project included cost reduction of over €10 million.

2007 - on going Kingspan, Introducing, leading, training, and coaching a major new team of Six Sigma Green Belts into the business to solve problems and reduce costs. Use of Experimental Design techniques to develop a new product and ensuring market readiness. Cost savings over £4 million during the 10 years.  


2016 Dakin-Flathers, Leading and implementing a programme, over 6 months, to introduce Advanced Continuous Improvement tools and techniques within the business. This project led to business improvements including the development of ‘a shop’ and machine OEE improvements. 


2014 Flow Energy, Acting as Interim Quality Manager with responsibility for both QA and QC activities. Flow is an Energy provider; this project involved the development of a domestic boiler which generated electricity while heating the house with natural gas.


2013 Mahle Filter Systems, Leading Supply chain interventions for complex problem solving in India (New Delhi / Pune / Chennai) and China. Leading the development of a new product and production line within Mahle Chennai factory to ensure a Lean and Agile Assembly process. Mahle Filter Systems is a Tier 1 supplier in the Automotive sector.


2006 – 2011 Behr, Leading a cultural change programme teaching/ coaching Six Sigma across the group in Germany, France, China, USA, South Africa, Spain, Brazil and Czech Republic. Problem solving consultancy projects in Germany and Czech Republic. Cost saving of over €20M.


2010 ABiGEM, Turkey. Leading training in Lean Tools and Techniques. Writing a textbook, published to support the programme detailing the Lean tools and techniques with examples from the programme in Turkey.

2016 -2017 UK, JAS, delivering a Management Development Programme for the Construction management team including the introduction and implementation of digital working practices.


2017 UK, Liquibox Leading the training of Lean Six Sigma Green and Black Belt. This company produces packaging for the Food Industry.


2012 -2015 Stuttgart, Czech Republic BTT, On-going support for new product development and problem solving in both production factories. Also provided support to investigate and solve customer claims for current product.


2015 – 2017 Wales, DMM Engineering Ltd. Leading the Six Sigma training and Lean consultancy support for both problem solving and new product development. DMM is the only manufacturer of mountaineering equipment in the UK and suppliers the Global market.


2015 UK, Access Community Services, Leading the development of a detailed process map of the company’s activities within the Adult Social Care sector as part of the Investors in People award.


2009 -2016 UK JRI, Working with the Manufacturing Manager on Continuous Improvement activities across the company. JRI is a medical prosthetics provider.


2013 Ireland BE Seating, Leading training on Global 8D, Statistical Engineering and problem solving on customer issues with respect to the quality of airplane seating.


2012 Austria, Germany, China Mahle Filter Systems, Working as a Master Black Belt within a production cell for a new product - solving complex problems in the supply network.


2012 Denmark, DONG, Leading the training of internal DONG Improvement Consultancy to develop Six Sigma skills.


2011 UK NHS, Leading the training of a team of NHS Continuous Improvement Managers teaching the tools and techniques of Six Sigma and Lean.


2011 UK Ceres Power, Leading the training of a bespoke programme based on Six Sigma and Statistical Engineering to Engineers working on the development of a new ‘green’ boiler for domestic use.


2011 UK Space, Leading the development of a detailed process map of the company’s activities within the Construction Sector.


2010 Sunderland County Council, Leading the training of Six Sigma teaching for key workers within the Council as part of a Continuous Programme to improve Council Services.


2010 UK Woollam Egg Farm, Consultancy project to double the egg production moving the business to a higher tier in the supply network for free range eggs in the UK.


2007 Denmark, USA, Danfoss, leading an internal Continuous Improvement team developing Six Sigma skills.


2005 – 2006 UK Rolls-Royce working as a Consultant within the Rolls-Royce Supplier network team to improve the delivery and quality performance of the suppliers.


2004 -2005 Scotland, Rolls-Royce Acting as the Interim Quality Manager of a small team of quality professionals for Inchinnan Factory, producing rotating components for the Aerospace and Energy sectors.


2003-2004 UK Manthorpe, Acting General Manager with P/L and Balance Sheet responsibility, leading the implementation of ERP system.


2003 Germany, Italy, Poland, Hungary Unilever, Delivered Unilever TPM programme, ‘Quality Maintenance’ programmes across sites.


2002 Norway Rolls-Royce – Energy Acting as an Internal Consultant working with the local Foundry management to rebrand the company from Vickers to Rolls-Royce and to increase the profitability of the business.


1998-2002 Germany, Hong Kong, USA, Canada, Norway Rolls-Royce – Energy and Corporate Acting as an Internal Consultant providing support for the RR Quality Strategy implementation and ‘Cash Race’ working capital reduction programme.


1988 – 1998 UK Rolls-Royce – Nuclear Working as Statistician and Team Leader Production implementing Lean principles from a ‘Push’ system to a ‘Pull’ system and a 40% reduction in manufacturing leadtimes. Implementation of ERP and SAP.

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